Semiconductor device having a through-substrate via

ABSTRACT

Semiconductor devices are described that include a via that extends only partially through the substrate. Through-substrate vias (TSV) furnish electrical interconnectivity to electronic components formed in the substrates. In implementations, the semiconductor devices are fabricated by first bonding a semiconductor wafer to a carrier wafer with an adhesive material. The semiconductor wafer includes an etch stop disposed within the wafer (e.g., between a first surface a second surface of the wafer). One or more vias are formed through the wafer. The vias extend from the second surface to the etch stop.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation under 35 U.S.C. §120 of U.S.patent application Ser. No. 13/342,420, filed Jan. 3, 2012, entitled“SEMICONDUCTOR DEVICE HAVING A THROUGH-SUBSTRATE VIA,” which is herebyincorporated by reference in its entirety.

BACKGROUND

Consumer electronic devices, in particular, mobile electronic devicessuch as smart phones, tablet computers, and so forth, increasinglyemploy smaller, more compact components to furnish their users withdesired features. Such devices often employ three dimensional integratedcircuit devices (3D IC). Three-dimensional integrated circuit devicesare semiconductor devices that employ two or more layers of activeelectronic components. Through-substrate vias (TSV) interconnectelectronic components on the different layers (e.g., differentsubstrates) of the device allowing the devices to be integratedvertically as well as horizontally. Consequently, three-dimensionalintegrated circuit devices can provide increased functionality within asmaller, more compact footprint than do conventional two-dimensionalintegrated circuit devices.

SUMMARY

Semiconductor devices are described that include one or more vias thatextend only partially through the substrate. The vias, which may bethrough-substrate vias (TSV), furnish electrical interconnectivity toelectronic components formed in the substrates. In implementations, thesemiconductor devices are fabricated by first bonding a semiconductorwafer to a carrier wafer with an adhesive material to provide mechanicalsupport to the semiconductor wafer during later fabrication steps. Thesemiconductor wafer includes an etch stop disposed within the wafer(e.g., between a first surface and a second surface of the wafer). Oneor more vias are then formed through the wafer that extend from thesecond surface of the wafer to the etch stop.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

DRAWINGS

The detailed description is described with reference to the accompanyingfigures. The use of the same reference numbers in different instances inthe description and the figures may indicate similar or identical items.

FIG. 1 is a diagrammatic partial cross-sectional view illustrating asemiconductor device having one or more vias in accordance with anexample implementation of the present disclosure.

FIGS. 2A and 2B are flow diagrams illustrating a process in an exampleimplementation for fabricating semiconductor devices having one or morevias, such as the device shown in FIG. 1.

FIG. 3A through 3F are diagrammatic partial cross-sectional viewsillustrating the fabrication of a semiconductor device having one ormore vias such as the device shown in FIG. 1, in accordance with theprocess shown in FIG. 2.

DETAILED DESCRIPTION Overview

Through-silicon vias (TSVs) are vertical electrical interconnectionsutilized to create three dimensional (3D) integrated circuit devices.For example, an integrated circuit die may be stacked over a siliconwafer. By interconnecting the integrated circuit die with integratedcircuits formed in the silicon wafer, the integrated circuit die and theintegrated circuits in the silicon wafer behave as a single device. Inan embodiment, a TSV may extend completely through the substrate (waferor die) to provide electrical interconnections between integratedcircuit devices formed in the substrate and other components associatedwith the integrated circuit devices (e.g., the integrated circuit die).

Accordingly, wafer-level packaging techniques are described to allowpackaging of multiple die into a single wafer-level package device. Thesemiconductor devices include vias that extend partially through thesubstrate of the devices to allow for additional routing near a surfaceof the semiconductor device. In one or more implementations, thesemiconductor devices are fabricated by first bonding a semiconductorwafer to a carrier wafer with an adhesive material. The semiconductorwafer includes an etch stop disposed within the wafer (e.g., between afirst surface a second surface of the wafer). Then, one or more vias areformed through the wafer that extend from about the second surface tothe etch stop. In one or more implementations, an integrated circuit dieis disposed over the second surface of the wafer. An encapsulationstructure may be formed over the second surface to at leastsubstantially encapsulate the integrated circuit die. A stiffener may beformed over the encapsulation structure to furnish mechanical support tothe device. In an implementation, the stiffener may be fabricated froman Alloy forty-two (42) composition.

In the following discussion, an example semiconductor device is firstdescribed. Exemplary procedures are then described that may be employedto fabricate the example semiconductor device.

Example Implementations

FIG. 1 illustrates a semiconductor device 100 in accordance with exampleimplementations of the present disclosure. As shown, the semiconductordevice 100 includes a substrate 102 (e.g., a portion of a semiconductorwafer). The substrate 102 includes alignment marks 104 that allow foralignment of the substrate 102 during semiconductor fabricationprocesses. The substrate 102 also includes a first surface 106 and asecond surface 108.

The substrate 102 comprises a base material utilized to form integratedcircuit devices 110 through various fabrication techniques such asphotolithography, ion implantation, deposition, etching, and so forth.The substrate 102 may be configured in a variety of ways. For example,the substrate 102 may comprise an n-type silicon wafer or a p-typesilicon wafer. In an implementation, the substrate 102 may comprisegroup V elements (e.g., phosphorus, arsenic, antimony, etc.) configuredto furnish n-type charge carrier elements. In another implementation,the substrate 102 may comprise group IIIA elements (e.g., boron, etc.)configured to furnish p-type charge carrier elements.

The integrated circuit devices 110 may be configured in a variety ofways. For example, the integrated circuit devices 110 may be digitalintegrated circuit devices, analog integrated circuit devices,mixed-signal circuit devices, and so forth. In implementations, theintegrated circuit devices may comprise digital logic devices, analogdevices (e.g., amplifiers, etc.), combinations thereof, and so forth. Asdescribed above, the integrated circuit devices 110 may be fabricatedutilizing various fabrication techniques (e.g., front-end-of-line (FEOL)fabrication techniques). For example, the integrated circuit devices 110may be fabricated through complementary metal-oxide-semiconductor (CMOS)techniques, bi-polar semiconductor techniques, and so on.

As shown in FIG. 1, the device 100 also includes conductive layers 112.In an implementation, the conductive layers 112 may comprise conductive(e.g., contact) pads, redistribution structures, or the like. In afurther implementation, the conductive layers 112 may include seed metaland/or barrier metal layers to allow for plated-line formation. Thenumber and configuration of the conductive layers 112 may vary dependingon the complexity and configuration of the integrated circuit devices110, and so forth. The conductive layers 112 may provide electricalinterconnections through which the integrated circuit devices 110 areinterconnected to other electronic components associated with the device100, such as printed circuit boards, or other integrated circuit devices110 that are disposed within the device 100. In implementations, theconductive layers 112 may comprise an electrically conductive material,such as a metal material (e.g., aluminum, copper, etc.), or the like.

As described above, the conductive layers 112 furnish electricalinterconnection between various electrical components associated withthe device 100. For instance, a first conductive layer 112 deployed overthe second surface 108 may furnish an electrical interconnection betweenan integrated circuit device 110 to solder bumps 114. Solder bumps 114and micro-solder bumps 115 are provided to furnish mechanical and/orelectrical interconnection between the conductive layers 112 andcorresponding pads formed on the surface of a printed circuit board. Inan implementation, the solder bumps 114 and micro-solder bumps 115 maybe fabricated of a lead-free solder such as a Tin-Silver-Copper(Sn—Ag—Cu) alloy solder (i.e., SAC), a Tin-Silver (Sn—Ag) alloy solder,a Tin-Copper (Sn—Cu) alloy solder, and so on. However, it iscontemplated that Tin-Lead (PbSn) solders may be used. As shown in FIG.1, a first array 113 of micro-solder bumps 115 are disposed over thefirst surface 106 and a second array 117 of solder bumps 114 aredisposed over the second surface 108 of the device 100.

Bump interfaces 116 may be applied to the conductive layers 112 toprovide a reliable interconnect boundary between the conductive layers112 and the solder bumps 114. For instance, in the semiconductor device100 shown in FIG. 1, the bump interface 116 comprises under-bumpmetallization (UBM) 118 applied to the conductive layers 112 of thesubstrate 102. The UBM 118 may have a variety of compositions. Forexample, the UBM 118 include multiple layers of different metals (e.g.,Aluminum (Al), Nickel (Ni), Copper (Cu), etc.) that function as anadhesion layer, a diffusion barrier layer, a solderable layer, anoxidation barrier layer, and so forth. However, other UBM structures arepossible. In another implementation, the bump interfaces 116 maycomprise copper pillars, or the like.

In implementations, the device 100 may employ a conductive layer 112implemented in a Redistribution Layer (“RDL”) configuration. The RDLconfiguration employs a redistribution structure 120 comprised of athin-film metal (e.g., aluminum, copper, etc.) rerouting andinterconnection system that redistributes the conductive layers 112 toan area array of bump interfaces 116 (e.g., UBM pads) that may be moreevenly deployed over the surface of the device 100. As shown in FIG. 1,the device 100 may also include a RDL structure 121 disposed over thefirst surface 106 to further provide electrical interconnectionfunctionality to components (e.g., integrated circuit devices 110, TSVs,etc.) associated with the device 100.

The solder bumps 114 and the micro-solder bumps 115 are subsequentlyplaced over these bump interfaces 116 to form bump assemblies 122 andbump assemblies 123, respectively. Thus, viewed together, the solderbumps 114, the micro-solder bumps 115, and associated bump interfaces116 (e.g., UBM 118, copper pillars) comprise bump assemblies 122, 123,respectively, that are configured to provide mechanical and/orelectrical interconnection of the integrated circuit devices 110 toother electronic devices, such as a printed circuit board or another die(as described herein).

While FIG. 1 illustrates a device 100 that employs a RedistributionLayer (“RDL”) configuration, it is contemplated that the device 100illustrated and described herein may also employ a Bump-On-Pad (“BOP”)configuration. The BOP configuration may employ a conductive layer 112disposed under the bump interface 116 (e.g., UBM pads).

Conductive pads 124, 126 (e.g., conductive layers 112) may be disposedin the substrate 102. As shown in FIG. 1, the conductive pads 124 aredisposed within the substrate 102 and the conductive pads 126 aredisposed near the surface 108. In some implementations, the conductivepads 126 are disposed over a surface of the substrate 102. Theconductive pads 124, 126 may be configured in a variety of ways. In anexample, the conductive pads 124, 126 may be comprised of aluminum. Inanother example, the conductive pads 124, 126 may be comprised ofcopper. However, other examples are possible.

As shown in FIG. 1, through-substrate vias (TSVs) 128 extend from thesurface 106 to the conductive pads 124. Thus, the conductive pads 124may be configured to function as an etch stop 125 during formation ofthe through-silicon vias 128 (TSVs). In one or more implementations, theetch stop 125 may comprise a metal 1 layer, a metal 2 layer, a metal 3layer, a metal 4 layer, or the like. The conductive pads 124 also serveto provide electrical interconnection functionality between a TSV 128(which is connected to a solder bump 114 of the first array 113 of bumpassemblies 122) and other associated electronic components (e.g.,integrated circuit devices 110). As shown, the TSVs 128 do not extendthe entire depth (D) of the substrate 102 (e.g., a TSV 128 extends onlypartially through the substrate 102). For instance, in one example, theTSVs 128 may have a depth of about fifty microns (50 um) to about onehundred microns (100 um), while the depth (D) of the substrate 102 isabout sixty-five microns (65 um) to about one hundred and twenty microns(120 um). However, it is contemplated that in other exampleimplementations, the depths of the TSVs 128 and the substrate 102 mayvary depending on various applications. In this manner, additionalrouting (e.g., additional RDL structures 120) and/or additionalintegrated circuits devices (e.g., integrated circuit devices 110) maybe disposed near the second surface 108 of the substrate 102 due toadditional space realized from the TSVs 128 not extending the entiredepth of the substrate 102. The TSVs 128 may be configured in a varietyof ways. For instance, in one specific example, the TSVs 128 may have anaspect ratio ranging from about four to one (4:1) to ten to one (10:1).In implementations, the conductive pads 124 may comprise a metal layer,such as copper, aluminum, or the like.

FIG. 1 also illustrates a dielectric layer 127 (e.g., an interlayer)that is disposed above the conductive pad 124 and extends at leastsubstantially the width of the substrate 102. As shown, the dielectriclayer 127 is positioned proximate to (e.g., adjacent or above) theconductive pads (etch stops 125). The dielectric layer 127 may beutilized to slow the etch rate of the TSVs 128. For example, during afabrication step, a first TSV 128 and a second TSV 128 may be formed.However, a first etch rate (of the first TSV 128) may be faster (e.g.,greater) than a second etch rate (of the second TSV 128). Thus, thedielectric layer 127 may manage to slow the first etch rate such thatthe second etch rate is approximately equal to the first etch rate(e.g., the etch rates may be approximately equal when the etchingmaterial encounters the etch stops). In one or more implementations, thedielectric layer 127 may comprise multiple layers of at least one of:silicon nitride, phosphorous doped silicon oxide, or undoped siliconoxide.

As shown in FIG. 1, the conductive pads 126 are disposed near (e.g.,over) the second surface 108 and serve to provide electricalinterconnection functionality between the RDL structures 120 and otherelectronic components of the device 100. In an embodiment, theconductive pads 126 may be disposed over a surface of the substrate 102.The conductive pads 126 may provide an electrical interconnectionbetween a RDL structure 120 and an integrated circuit device 110 that isdisposed between a conductive pad 124 (etch stop 125) and a conductivepad 126.

As described above, the through-silicon via 128 (TSV) extends partiallythrough the substrate 102 to at least one conductive layer 112 such asthe etch stop 125 of the substrate 102. For example, the TSV 128 isillustrated as being disposed within the substrate 102 and extends tothe etch stops 125. Thus, in an implementation, the TSV 128 (TSVs 128)does not extend through the substrate 102 (e.g., the TSV 128 does notextend from the surface 106 to the surface 108). As shown in FIG. 1, theTSV 128 includes a conductive material 130 that furnishes an electricalinterconnection between a first conductive layer 112 (e.g., conductivepad 124) of the substrate 102 and a solder bump 114 of the first array113 of bump assemblies 123. The conductive material 130 extendsvertically through the TSV 128 as well as horizontally over the firstsurface 106. The portion of the conductive material 130 extendinghorizontally over the first surface 106 serves to function as the RDLstructure 121. For instance, the conductive material 130 may provide anelectrical interconnection between an integrated circuit device 110 anda solder bump 114. In an implementation, the conductive material 130 maycomprise a metal material, such as copper, or the like.

The TSV 128 includes an insulating liner 132 to electrically isolate theconductive material 130 disposed in the TSVs 128 from the top wafer 104.Thus, the insulating liner 132 serves to prevent shorting of theconductive material 130 with the substrate 102. As illustrated in FIG.1, the insulating liner 132 is deposited in the TSVs 128 such that theliner 132 at least substantially lines the TSVs 128. The insulatingliner 132 may be configured in a variety of ways. For example, theinsulating liner 132 may be an insulating material, such as an oxidematerial (SiO₂), a nitride material, combinations thereof, or the like.The insulating liner 132 is formed by depositing the insulating materialin the TSVs 128 and then etching the insulating material at the bottomof the TSVs 128 while preserving the insulating liner 132 along thesides of the TSVs 128. In one or more implementations, the insulatingmaterial may be deposited via plasma enhanced chemical vapor deposition(PECVD) techniques and then anisotropically etching the insulatingmaterial down to the conductive pad 124 to form the liner 132.

The first array 113 of bump assemblies 123 may be in electrical contactwith an integrated circuit die 134 to extend system on a chip (SoC)capabilities to the device 100. For instance, the integrated circuit die134 may be comprised of digital circuitry, analog circuitry, ormixed-signal circuitry.

Additionally, as shown in FIG. 1, the device 100 includes a polymerlayer 136 disposed over the first surface 106 to furnish stability tothe first array 113 of bump assemblies 123. In one or moreimplementations, a low temperature polybenzobisoxazole (PBO) process maybe utilized to form the polymer layer 136 over the first surface 106.The low temperature PBO process may occur in temperatures ranging fromabout one hundred and fifty degrees Celsius (150° C.) to about twohundred degrees Celsius (200° C.). In an implementation, the lowtemperature PBO process may occur at a temperature of about one hundredand seventy-five degrees Celsius (175° C.). The low temperature PBOprocess serves to form the polymer layer 136 while not harming alreadycompleted fabrication steps (integrated circuit devices 110, temporaryadhesive layer (see temporary adhesive layer 322 in FIG. 3C).).

An encapsulation structure 138 is disposed over the polymer layer 136 toprovide support and to at least substantially hold the integratedcircuit die 134 in position. As shown in FIG. 1, the encapsulationstructure may at least substantially encapsulate the integrated circuitdie 134. In one or more implementations, the encapsulation structure 138may be comprised of a suitable molded composition, or the like.

As illustrated in FIG. 1, the device 100 further includes a stiffener140 disposed over the encapsulation structure 138 to furnish mechanicalsupport to the device 100. The stiffener 140 may have a coefficient ofthermal expansion (CTE) that is comparable to the CTE of the device 100(e.g., substrate 102, etc.). Thus, the stiffener 140 may be configuredin a variety of ways. For example, the stiffener 140 may comprise asilicon material that has a CTE comparable to the CTE of the device 100.In another example, the stiffener 140 may be comprised of a metalcomposition that has a CTE comparable to the CTE of the device 100. Inan implementation, the metal material may be Alloy forty-two (42)composition (e.g., a nickel iron (Ni—Fe) alloy), or the like.

The semiconductor device 100 also includes a first and second polymerlayers 142, 144 to furnish insulation to the one or more conductivelayers 112 (e.g., RDL structure 120, conductive pads 126). For example,the polymer layers 142, 144 may be utilized to insulate the one or moreconductive layers 112 from later processing steps. In an implementation,the polymer layers 142, 144 may be formed through a low temperature PBOprocess, or the like.

Example Fabrication Processes

FIGS. 2A and 2B illustrate an example process 200 that employswafer-level packaging techniques to fabricate semiconductor devices,such as the semiconductor device 100 shown in FIG. 1. FIGS. 3A through3F illustrate sections of example wafers that may be utilized tofabricate semiconductor devices 300 (such as the semiconductor device100 shown in FIG. 1). A semiconductor wafer, such as wafer 302 shown inFIG. 3A, includes a first surface 304 and a second surface 306. Thewafer 302 also includes one or more integrated circuit devices 308formed through FEOL fabrication techniques. For example, the integratedcircuit devices 308 may be fabricated through complementarymetal-oxide-semiconductor (CMOS) techniques, bi-polar semiconductortechniques, and so on. In one or more implementations, the integratedcircuit devices 308 may comprise digital logic devices, analog devices(e.g., amplifiers, etc.), combinations thereof, and so forth.

As shown in FIG. 3A, the devices 300 also include multiple conductivelayers 310. The conductive layers 310 include a first (e.g., topmost padas shown in FIG. 3A) conductive pad(s) 312 and a second (e.g.,bottommost pad as shown in FIG. 3A) conductive pad(s) 314. In one ormore implementations, the conductive pads 312, 314 may be aluminum, orthe like. As shown, the first conductive pad(s) 312 are disposed overthe first surface 304, and the second conductive pad(s) 314 are disposedwithin the wafer 302 to function as an etch stop (e.g., etch stop 315)during formation of one or more TSVs (described herein). As shown, thesecond conductive pad(s) 314 are disposed proximate (e.g., adjacent ornear) a dielectric layer 316, which is configured to manage one or moreetch rates during formation of the TSVs. For example, a first etch rateof a first TSV may be faster (e.g., greater) than a second etch rate ofa second TSV. Thus, the dielectric layer 316 may manage to slow thefirst etch rate such that the second etch rate is approximately equal tothe first etch rate as described above. The dielectric layer 316 mayalso include a diffusion barrier material (e.g. silicon nitride, siliconcarbide, etc.) to protect the integrated circuit devices 308 formedthrough FEOL fabrication techniques from contamination introduced duringthe metallization and interlayer dielectric deposition. The devices 300may also include alignment marks 318 to align the wafer 302 during laterfabrication processes (e.g., bonding to a carrier wafer, formation ofthe TSVs, etc.). In an implementation, visible light and/or infraredlight alignment techniques may be utilized to align the wafer 302.

As shown in FIG. 2A, a carrier wafer is bonded to a semiconductor wafer(Block 202). As shown in FIG. 3A, a passivation layer 320 is disposedover the first surface 304 of the first conductive pad(s) 312. Thepassivation layer 320 initially at least substantially encapsulates theconductive pad(s) 312 before the passivation layer 320 is selectivelyetched to at least partially expose the conductive pad(s) 312. Asuitable temporary adhesive layer 322 is deposited over the passivationlayer 320 to allow a carrier wafer 324 to be bonded to the semiconductorwafer 302. In an implementation, the carrier wafer 324 may be a siliconwafer, or the like.

The semiconductor wafer is then subjected to a suitable backgrindingprocess (Block 204). As shown in FIG. 3B, the second surface 306 of thewafer 302 is subjected to a backgrinding process to thin the wafer 302.A hardmask layer is then formed over the second surface of thesemiconductor wafer (Block 206). A hardmask layer 326 is formed over thesurface 306 to protect portions of the wafer 302 during formation of theTSVs (see FIG. 3B). In an implementation, the hardmask layer 326 may becomprised of a dual oxide-nitride hardmask, or the like.

One or more TSVs are then formed within the semiconductor wafer (Block208). The TSVs may be formed by etching TSV regions in the semiconductorwafer (Block 210). For example, a photoresist layer is formed over thehardmask layer 326. The TSV regions 328 are formed by selectivelypatterning and etching photoresist layer regions (e.g., unexposedregions of the photoresist layers) to begin formation of the TSVs 330.As shown in FIG. 3C, the TSVs 330 extend from about the second surface306 to the second conductive pads 314 (e.g., etch stops 315).

An insulating layer is deposited within the TSV regions (Block 212). Asshown in FIG. 3C, an insulating layer 332 is deposited within the TSVs330 to electrically isolate the TSVs 330 from the wafer 302. In animplementation, the insulating layer 332 may be an oxide layer (SiO₂),or the like. An anisotropic dry etch process is used to clear theinsulating layer from the bottom of the TSV while retaining thisinsulating layer on the sidewalls of the TSV. Next, a diffusion barriermetal 334 (e.g., Ti, etc.) and a seed metal 334 are deposited over thesecond surface 306. The diffusion barrier metal 334 and seed metal 334may be patterned (through suitable lithography steps) to provideelectrical interconnections between various components (e.g., integratedcircuit devices 308, solder bumps, etc.).

A conductive material is deposited within the TSV regions and over thesecond surface (Block 214). As shown in FIG. 3C, a conductive material336 is deposited within the TSV regions 328 to form TSVs 330 (e.g.,forming a via for electrical interconnection functionality) and over thesecond surface 306 to form a RDL structure 331 (e.g., the TSV 330 filland the formation of the RDL structure 331 may be accomplished in asingle plating (e.g., copper plating) process). The RDL structure 331may serve to provide an electrical interconnection between the TSVs 330,which are in electrical communication with the integrated circuitdevices 308, and one or more solder bumps (described herein). In one ormore implementations, the conductive material 336 may be depositedthrough one or more suitable plating techniques. For example, a coppermaterial may be copper plated to deposit the conductive material 336within the TSVs 330 and over the second surface 306. Thus, theconductive material 336 may serve as an electrical interconnectionwithin the TSVs 330 as well as function as a redistribution structure.

A dielectric material is deposited over the second surface of thesemiconductor wafer (Block 216). A shown in FIG. 3C, a dielectricmaterial 338 is deposited over the second surface 306 of thesemiconductor wafer 302. In an implementation, the dielectric material338 may be a low temperature polybenzobisoxazole (PBO). The dielectriclayer 338 may be patterned and etched (through suitable lithographyprocesses) to at least partially expose the conductive material 336.

As shown in FIG. 2A, an integrated circuit die is attached to thesemiconductor wafer (Block 218). Attachment of the integrated circuitdie includes forming a first array of solder bumps over the secondsurface (Block 220). A first array 340 of mini-solder bumps 342 areformed over the second surface 306 (e.g., over the etched portions ofthe dielectric layer 338). For example, one or more mini-solder balls(pre-reflowed mini-solder bumps 342) are positioned (through a solderball placement stencil, or the like) over the etched portions of thedielectric layer 338 that at least partially expose the conductivematerial 336. It is contemplated that flux may be applied to theconductive material 336 to remove oxidation from the surface of theexposed conductive material 336 regions. The mini-solder balls are thenreflowed to form mini-solder bumps 342. The conductive material 336 maybe patterned to form a bump interface 341. For example, the bumpinterface 341 may be configured as an UBM 344. In another example, thebump interface 341 may be configured as a copper pillar. An integratedcircuit die is then positioned over the solder bumps (Block 222). Asshown in FIG. 3C, an integrated circuit die 346 is positioned over themini-solder bumps 342. The mini-solder bumps 342 are configured tofurnish electrical interconnection functionality between the integratedcircuit die 346 and the TSVs 330. The integrated circuit die 346 may beconfigured in a variety of ways. For example, the integrated circuit die346 may be a digital integrated circuit die. In another example, theintegrated circuit die 346 may be an analog integrated circuit die. Inyet another example, the integrated circuit die 346 may be amixed-signal integrated circuit die.

As shown in FIG. 2B, an encapsulation structure is formed over thesecond surface of the semiconductor wafer (Block 224). An encapsulationstructure 348 is then formed over the second surface 306 (e.g., over thedielectric layer 338) to encapsulate the integrated circuit die 346 (seeFIG. 3D). Thus, the encapsulation structure 348 may at leastsubstantially hold the integrated circuit die 346 in position whileinsulating the integrated circuit die 346 from further processing steps.In an implementation, the encapsulation structure 348 may be comprisedof a suitable molded compound, or the like.

A stiffener is deposited over the encapsulation structure (Block 226).As shown in FIG. 3D, a stiffener 350 is deposited (e.g., formed) overthe encapsulation structure 348 to furnish mechanical strength to thedevice 300. As described above, the stiffener 350 may have a CTE that iscomparable to the CTE of the device 300 (e.g., wafer 302). In one ormore implementations, the stiffener 350 may be a silicon material or ametal material (e.g., Alloy 42).

The carrier wafer is then debonded (e.g., removed) from thesemiconductor wafer (Block 228). For example, the carrier wafer 324 maybe debonded from the wafer 302 by heating the temporary adhesive layer322 sufficiently to allow for removal of the carrier wafer 324 (see FIG.3E). Once the carrier wafer is removed, one or more conductive layersare formed over the first surface of the semiconductor wafer (Block230). As shown in FIG. 3E, a first polymer layer 352 may be depositedover the first surface 304 and selectively patterned to at leastpartially expose the first conductive pad(s) 312. Once the firstconductive pad(s) 312 are at least partially exposed, a conductive layer354 may be formed (e.g., deposited and patterned) over the polymer layer352. As described above, a diffusion barrier metal and a seed metal(e.g., such as diffusion barrier metal 334 and a seed metal 334) mayfirst be deposited and patterned before deposition of the conductivelayer 354. In an implementation, the conductive layer 354 may beconfigured as a redistribution structure 355, or the like. Once theconductive layer 354 is formed over the polymer layer 352, a secondpolymer layer 356 may be deposited over the polymer layer 352 and theconductive layer 354. The polymer layer 356 is then patterned to atleast partially expose the conductive layer 354. In an implementationthe first and second polymer layers 352, 356 may be formed through oneor more suitable low temperature PBO processes. A conductive layer 358is then deposited over the polymer layer 356 and patterned to form abump interface 360. In an implementation, the bump interface 360 may beconfigured as a UBM 362 (see FIG. 3E). In another implementation, thebump interface 360 may be configured as a copper pillar.

As shown in FIG. 2B, suitable wafer-level packaging processes may beemployed to segment and package the individual semiconductor devices(Block 232). For example, a second array of solder bumps are formed overthe first surface of the semiconductor wafer (Block 234). The secondarray 364 of solder bumps 365 are formed over the conductive layer 358(e.g., bump interface 360). As described with respect to the first array340 of solder bumps 342, a flux may be applied to the bump interfaces360 before one or more solder balls are positioned over the bumpinterfaces 360. Once positioned, the solder balls are subjected to asuitable reflow process to form solder bumps 365. In one or moreimplementations, the segmented semiconductor devices may comprise waferchip-scale package devices.

CONCLUSION

Although the subject matter has been described in language specific tostructural features and/or process operations, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above.Rather, the specific features and acts described above are disclosed asexample forms of implementing the claims.

What is claimed is:
 1. A semiconductor device comprising: a substratehaving a first surface and a second surface, the substrate including adielectric layer, an alignment mark for alignment of a carrier waferwith the substrate, an etch stop disposed within the substrate, and oneor more integrated circuit devices formed therein; a first array ofsolder bumps disposed over the first surface; a second array of solderbumps disposed over the second surface; and a via extending from aboutthe second surface through the dielectric layer to the etch stop,wherein at least one of the integrated circuit devices is electricallyconnected to at least one solder bump of the second array of solderbumps through the via.
 2. The semiconductor device as recited in claim1, further comprising a conductive material disposed at partially withinthe via region and at least partially over the second surface.
 3. Thesemiconductor device as recited in claim 1, further comprising aredistribution structure disposed over the first surface to provide anelectrical connection between at least one solder bump of the firstarray of solder bumps and at least one integrated circuit device of theone or more integrated circuit devices.
 4. The semiconductor device asrecited in claim 1, further comprising the carrier wafer bonded to thesubstrate, the carrier wafer for providing mechanical support to thesubstrate.
 5. The semiconductor device as recited in claim 1, furthercomprising: an integrated circuit die disposed over at least one solderbump of the second array of solder bumps; an encapsulation structuredisposed over the second surface of the substrate to at leastsubstantially encapsulate the integrated circuit die; and a stiffenerdisposed over the encapsulation structure to furnish mechanical supportto the substrate.
 6. The semiconductor device as recited in claim 5,wherein the stiffener comprises an Alloy 42 composition.